Beam receptacle and method

ABSTRACT

A device for creating a receptacle within preformed walls, the preformed walls having an internal wall and an external wall such that a curable material may be poured therebetween. The device having a first, second, third, and fourth panel that are interconnected and receive a fifth panel at an inner edge thereof such that an opening is defined by the first, second, third, and fourth panel at an outer edge thereof which is distal to the fifth panel. Inserting the device into a cavity defined through the internal wall such that the outer edge of the first, second, third, and fourth panels may be attached to the internal wall during pouring of the curable material. The opening adapted to receive a member therein.

FIELD OF THE INVENTION

[0001] This invention relates to the construction industry, and particularly to a device and method for creating a receptacle for receiving steel beams or wood girders at desired heights in walls consisting of insulated concrete forms or any poured concrete walls.

BACKGROUND OF THE INVENTION

[0002] The prior art teaches a method of constructing poured concrete walls in which modular wall preforms, each comprising a pair of high-density foam panels which are maintained in a parallel-spaced relationship by a series of bridging “webs” extending between and through and molded into the panels, are interlockingly stacked together to define a concrete form for the poured concrete wall. With reinforcing steel bars optionally suspended within the assembled wall form, preferably through use of hooks or other retainers provided on each bridging web, the concrete is thereafter poured between the panels to complete the wall.

[0003] Unlike other known methods of constructing poured concrete walls in which the form's panels are removed from the poured concrete wall prior to the complete curing thereof, in the method employing these modular foam-panel preforms, the preforms become a permanent part of the resulting composite wall structure, with the interlocking foam panels providing a highly-effective layer of insulation on both sides of the finished wall. Further, where the webbing terminates on the outside of each panel to define integral furring strips, finishing materials may be conveniently applied directly to the interior and exterior of the wall.

[0004] While this method has proved highly successful in constructing poured concrete basement walls, with first-floor joists supported by the wall's top surface in a conventional manner, there remains a need to provide a simple yet effective apparatus and method by which beams may be supported by the wall at a height beneath its top surface.

[0005] More specifically, in a first known method of making beam pockets in the foundation for receiving support beams is through precast construction, wherein the foundation units have beam pockets that are cast in place. These beam pockets support steel beams or wood girders at adjustable or desired locations along the wall. Therefore, in order to accommodate this need, special panels must be precast for each specific construction job, which seriously hampers or eliminates mass production runs.

[0006] In accordance with a second known method for creating beam pockets at a required location within the form walls, a void is created within the wall and a block consisting of either Styrofoam or wood is placed within the void. After the concrete is poured and allowed to set, the material used to fill in the void is chiseled out to expose the pocket. A drawback of this method is the inability to determine the correct fill of the poured concrete beneath the Styrofoam or wood blocks placed within the void. In addition, the removal of the Styrofoam or wood block is time consuming and may cause damage to the set concrete. Furthermore, the Styrofoam or wood blocks must be maintained between the two opposing form walls and, as a result, the void must be created through both walls such that two ledges are created to support the same, thereby preventing secure maintenance of the beam or girder.

[0007] The prior art does not address the need for a more effective method and device for creating beam pockets in perform walls at desired locations. Therefore, there remains a long standing and continuing need for an advance in the art of beam pocket creation that is simpler in both design and use, is more economical, efficient in its construction and use, and eliminates the need for complex and time expensive methods and devices for creating beam pockets.

SUMMARY OF THE INVENTION

[0008] Accordingly, it is a general object of the present invention to overcome the disadvantages of the prior art.

[0009] In particular, it is an object of the present invention to provide a device for creating beam receptacles in poured concrete walls.

[0010] It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls featuring ease of use.

[0011] It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that reduces or eliminates the presence of deleterious voids within the concrete around such beam receptacles.

[0012] It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that is economical in cost to manufacture and use.

[0013] It is another object of the present invention to provide a device and method for creating beam receptacles in poured concrete walls that that is easy to manufacture.

[0014] In keeping with the principles of the present invention, a unique device is disclosed for creating a receptacle to receive an I-beam or wood or metal girders used in creating floor systems within preformed walls that allow a curable material to be poured therein. The device is made of a top panel located above a bottom panel and interconnected by a pair of side panels. A back panel may be attached to the top, bottom, and side panels at an inner edge such that an opening is defined by the panels at an outer edge thereof and is distal to the back panel.

[0015] The device is inserted into a cavity defined by the internal wall of the preformed walls such that the outer edge of the panels is flush with the internal wall. A flange may extend from the outer edge of the panels to secure the device to the wall while the curable material is poured between the internal wall and the external wall of the preformed walls. In order to ensure the proper formation of the curable substance beneath the device, an aperture may be provided on the bottom panel to allow inspection of the curable material. In addition, the aperture may be used to accommodate a rebar therethrough to add structural integrity to the curable material below the device.

[0016] Such stated objects and advantages of the invention are only examples and should not be construed as limiting the present invention. These and other objects, features, aspects, and advantages of the invention herein will become more apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings and the claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] It is to be understood that the drawings are to be used for the purposes of illustration only by and not as a definition of the limits of the invention.

[0018] In the drawings, wherein similar reference characters denote similar elements throughout the several views:

[0019]FIG. 1 is a plan view of a device in an unassembled state illustrating one preferred embodiment thereof.

[0020]FIG. 2 is perspective view of the device assembled and mounted within a composite wall.

[0021]FIG. 3 is a partial cross-sectional view of the device in an assembled and mounted state taken along the line 3-3 of FIG. 2.

[0022]FIG. 4 is a partial cross-sectional view of the device in an assembled and mounted state taken along the line 4-4 of FIG. 5 illustrating receipt of a member within the device.

[0023]FIG. 5 is a perspective view of the device in an assembled and mounted state illustrating receipt of a member within the device.

DETAILED DESCRIPTION OF THE INVENTION

[0024] Referring to FIG. 1, therein is illustrated a device 10 in an unassembled state which is preferably used for creating beam pockets within insulated concrete form (“ICF”) walls or similar structures. It is to be understood that although a unitary method of construction of device 10 is herein illustrated in one preferred embodiment, device 10 may be constructed from several disjoined elements in alternate preferred embodiments. In addition, although several preferred dimensions or shapes may be assigned to device 10 in a preferred embodiment, it is to be understood that alternate sizes and shapes are also contemplated hereby.

[0025] Device 10 has at least a first panel 12, a second panel 14, a third panel 16, a fourth panel 18 and a fifth panel 20. First panel 12 has a first outer end 22 and an opposing first inner end 24 which are interconnected by a pair of first side ends 26. First side ends 26 may have at least a first attaching means 28 thereon that extend beyond an edge defined by said first side ends 26. For purposes of illustration but not limitation, first attaching means 28 may be a panel that extends along the length of said first side ends 26, or in an alternate preferred embodiment first attaching means 28 may extend along only a certain length of said first side ends 26.

[0026] Second panel 14 has a second outer end 30 and an opposing second inner end 32 interconnected by a second top end 34 and a second bottom end 36. Second top end 34 has an outer region 38 and an inner region 40. In a preferred embodiment, inner region 40 is angled towards second bottom end 36 at a predetermined angle and outer region 38 is substantially parallel to second bottom end 36. However, it is to be understood that second top end 34 may be substantially parallel to second bottom end 36 along the entire length thereof. Second bottom end 36 may have at least a second attaching means 37 thereon that extends beyond an edge defined by second bottom end 36. For purposes of illustration but not limitation, second attaching means 37 may be a panel that extends along the length of second bottom end 36, or in an alternate preferred embodiment second attaching means 37 may extend along only a certain length of second bottom end 36.

[0027] Third panel 16 has a third outer end 42 and an opposing third inner end 44 interconnected by a third top end 46 and a third bottom end 48. Third top end 46 has an outer portion 50 and an inner portion 52. In a preferred embodiment, inner portion 52 is angled towards third bottom end 48 at a predetermined angle and outer portion 50 is substantially parallel to third bottom end 48. However, it is to be understood that third top end 46 may be substantially parallel to third bottom end 48 along the entire length thereof. Third bottom end 48 may have at least a third attaching means 49 thereon that extends beyond an edge defined by third bottom end 48. For purposes of illustration but not limitation, third attaching means 49 may be a panel that extends along the length of third bottom end 48, or in an alternate preferred embodiment third attaching means 49 may extend along only a certain length of second bottom end 48.

[0028] Fourth panel 18 has a fourth outer end 54 and an opposing fourth inner end 56 which are interconnected by a pair of side edges 58. An aperture 60 is defined through fourth panel 18 and may be of any predetermined size. Fifth panel 20 is defined by a periphery 62 that is polygonal in a preferred embodiment. Periphery 62 of fifth panel 20 connects with first inner end 24, second inner end 32, third inner end 44, and fourth inner end 56 such that a substantially cross-shaped arrangement is achieved in an unfurled and unassembled state. Although device 10 is illustrated as being formed through stamping from unitary piece of material, it is to be understood that each of the individual panels may be independent of one another and affixed accordingly in any methods that are known in the art such as, but not limited to, welding of adhering. Various materials may also be used to construct device 10 and for purposes of illustration, but not limitation, in one preferred embodiment device 10 is constructed of a metal or a metal alloy such as, but not limited to, galvanized steel or aluminum. In addition, in an alternate preferred embodiment, device 10 may be constructed of polymeric materials such as, but not limited to, plastic. If polymeric materials are utilized, device 10 may also be constructed through methods of injection molding.

[0029] Now referring to FIGS. 2 and 3, device 10 is illustrated in an assembled and installed state within a composite wall 64. Composite wall 64 is formed by pouring a suitable curable material 66, such as concrete, between an interior panel 68 and an exterior panel 70. Composite wall 64 for purposes of illustration, but not limitation, may be obtained from AAB Building Supplies, Inc. of Ottawa, Canada, under the trademark BLUEMAXX® which uses a plurality of interlocking modular performs to construct a composite wall 64 of desired length.

[0030] Panels 12, 14, 16, and 18 are folded inwardly such that they rest at a substantially perpendicular angle to fifth panel 20, and panels opposing panels 12 and 18, and opposing panels 14 and 16 are in substantially parallel relations such that a receptacle 71 is defined by panels 12, 14, 16, 18, and 20. In a preferred embodiment, first panel 12 is adapted to be integral with inner region 40 and outer region 38 of second panel 14 and also integral with inner portion 52 and outer portion 50 of third panel 16 and covering panels 14 and 16. As such, first panel 12 has a forward region 72 and a rearward region 74, such that rearward region 74 is angled towards opposing fourth panel 18. In an assembled state, first attaching means 28 of first side ends 26 attach to an outer surface of second panel 14 and third panel 16. In addition, second attaching means 37 and third attaching means 49 are secured to an outer surface of fourth panel 18, attaching means 28, 37, and 49 may be secured to the respective panels through any appropriate method known in the art such as, but not limited to, welding or use of an adhesive.

[0031] When installing device 10 into a composite wall 64, a hole of an appropriate size is cut in interior panel 68 of composite wall 64 and device 10 is inserted therein such that receptacle 71 is accessible. In a preferred embodiment, a first flange 76 is formed on first panel 12 at a first outer end 22 thereof, a second flange 78 is formed on second panel 14 at second outer end 30 thereof, a third flange 80 is formed on third panel 16 at the third outer end 42 thereof, and a fourth flange 82 is formed on fourth panel 18 at the fourth outer end 54 thereof. In one preferred embodiment, flanges 76, 78, 80, and 82 may be formed by outwardly folding each respective panel or in an alternate preferred embodiment flanges 76, 78, 80, and 82 may be adhered to each respective panel in any appropriate method that is known in the art. At least a securing means 84 or a plurality thereof, may be used to firmly secure flanges 76, 78, 80, or 82 to interior panel 68. For purposes of illustration, but not limitation, securing means 84 may be a nail, screw, or bolt.

[0032] After device 10 is installed within composite wall 64, curable material 66 is poured into the space between interior panel 68 and exterior panel 70 and thus encloses device 10 therein. Aperture 60 may be used to ensure that sufficient curable material 66 exists beneath fourth panel 18. In addition, as more clearly illustrated in FIG. 4, a support element 86, such as a rebar, may be inserted through aperture 60 into the curable material 66 before curable material 66 has solidified. Support element 86 provides greater structural support for any member 88 received within receptacle 71. Now also referring to FIG. 5, member 88 is illustrated as received within receptacle 71. For purposes illustration, but not limitation, member 88 may be an I-Beam or wood or metal girder that may be used in the construction industry to support the construction of a floor thereon. Device 10 may be modified to form a receptacle 71 of a predetermined dimension to accommodate member 88 of varying dimensions.

[0033] While the above description contains many specificities, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of preferred embodiments thereof. Many other variations are possible without departing from the essential spirit of this invention. Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents. 

What is claimed is:
 1. A device for creating a receptacle within a cavity in a wall formed of two opposing walls and a poured material therebetween, comprising: at least a first panel, a second panel, a third panel, and a fourth panel; a fifth panel connected to an inner end of said first, second, third, and fourth panels in a substantially perpendicular manner and forming a substantially closed end; an opening being defined by an outer end of said first, second, third, and fourth panels at a point distal to said fifth panel; whereby said device is inserted into said cavity within the wall such that said opening to said receptacle is readily accessible.
 2. The device of claim 1, wherein said first, second, third, fourth, and fifth panels are made of a unitary planar sheet of material having a substantially cross-shape in an unassembled state.
 3. The device of claim 2, wherein said inner end of said first, second, third, and fourth panels are connected to said fifth panel in a manipulatable manner such that said first, second, third, and fourth panel may be moved from a planar relation with said fifth panel to a substantially perpendicular relation with said fifth panel.
 4. The device of claim 1, wherein at least an attaching means interconnects said first, second, third, and fourth panels in an assembled state.
 5. The device of claim 1, wherein said first panel is a top panel and extends from said fifth panel at an upward angle.
 6. The device of claim 1, wherein said first panel is a top panel and extends from said fifth panel at an upward angle for a rearward region and is substantially perpendicular to said fifth panel for a forward region.
 7. The device of claim 6, wherein said second panel and said third panel have a respective top end that is integral with said first panel.
 8. The device of claim 6, wherein said first panel has a side of side ends that have a least an attaching means thereon, and said attaching means connecting to said second panel and said third panel respectively.
 9. The device of claim 1, wherein said fourth panel is a bottom panel that has an aperture defined therethrough.
 10. The device of claim 9, wherein said aperture is of sufficient size to accommodate a rebar passing therethrough and into said poured material.
 11. The device of claim 1, wherein a laterally extending flange arises from said outer end of at least one of said first, second, third, and fourth panels and communicates with the wall.
 12. A device for creating a receptacle within a structure formed of a pair of parallel positioned walls such that a curable material can be poured therebetween, and at least a cavity defined through one of said walls for receiving said receptacle therein, the device comprising: at least a first panel, a second panel, a third panel, and a fourth panel being interconnected such that said first panel and said fourth panel are in substantially parallel relations, and said second panel and said third panel are in substantially parallel relations; a fifth panel connected to an inner end of said first, second, third, and fourth panels in a substantially perpendicular manner; an opening being defined by an outer end of said first, second, third, and fourth panels at a point distal to said inner end; whereby said device is inserted into said cavity within the wall such that said opening to said receptacle can receive a member therein.
 13. The device of claim 12, wherein said first panel is a top panel that extends from said fifth panel at a substantially upward angle for a predetermined rearward region and is substantially perpendicular to said fifth panel for a predetermined forward region; and said second panel and said third panel having a respective top end that is integral with said rearward region and forward region of said first panel.
 14. The device of claim 13, wherein the device is comprised of a material selected from a group consisting of wood, metal, and polymeric compounds.
 15. The device of claim 13, wherein said fourth panel has an aperture defined therethrough.
 16. The device of claim 13, wherein a laterally extending flange extends from said outer end of at least one of said first, second, third, and fourth panel in a direction distal to said opening.
 17. The device of claim 16, wherein said laterally extending flange receives a securing means therein to secure the flange to said wall.
 18. The device of claim 13, wherein said member is selected from a group consisting of an I-beam, a wood girder, and a metal girder for receiving a floor system thereon.
 19. A method of using a device to create a receptacle within a structure formed of an internal wall and an external wall such that a curable material can be poured therebetween, comprising the steps of: defining a cavity through said internal wall; assembling a first panel, a second panel, a third panel, and a fourth panel such that said first panel and said fourth panel are in substantially opposing relations, and said second panel and said third panel being in substantially opposing relations; attaching a fifth panel to an inner end of said first, second, third, and fourth panels to form a substantially closed end; defining an opening by an outer end of said first, second, third, and fourth panels a point distal to said fifth panel; inserting said device into said cavity of said internal wall such that an outer edge of said first, second, third, and fourth panels is substantially flush with said internal wall; pouring a curable material between said internal wall and said external wall and allowing the curable material to cure; inserting a member into said opening of said device.
 20. The method of claim 19, further comprising: creating an aperture through said fourth panel such that proper pouring of the curable material may be determined. 